Dc interconnect scheme for psu

ABSTRACT

An ATX compatible power supply unit having at least one DC power outlet and at least one DC power cable, the DC power outlet configured to support nominal contact resistances of less than 2.5 milliohms per contact or the DC power cable configured to support series resistances of less than 4 milliohms per linear foot of individual conductor is disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to Patent Application No. 12/XXX,XXX filedFeb. 26, 2010, entitled, “AC Interconnect Scheme for PSU,” by DonLieberman et al., and Patent Application No. 12/XXX,XXX filed Feb. 26,2010, entitled, “PCB Interconnect Scheme for PSU,” by Don Lieberman etal.

TECHNICAL FIELD

The present invention is directed to power supply units for computers,and more specifically to aspects relating to the efficiency of powersupply units for computers.

BACKGROUND

Personal computers require power supplies commonly referred to as powersupply units (PSU) to generate multiple voltages needed for properoperation. The main boards (motherboards) and peripherals of personalcomputers generally require multiple voltages for operation, including12 Volts, 5 Volts and 3.3 Volts. Power requirements of the centralprocessing units (CPU) on the motherboards and the video controllerintegrated circuit (IC) on the peripheral graphics cards have increaseddramatically. As a result, the overall power requirements of PSUs forpersonal computers have increased. High end gaming computers use powersupply units that source 1000 or 1200 watts, for example. Most PSUs areconfigured with industry standard AC input power connectors as describedby IEC (International Electrotechnical Commission) specification 60320.Thus, most PSUs for personal computers use IEC connector versions C13for power cord and C14 power inlets to supply AC power to the computer.However, as alternating current (AC) input currents increasedramatically, IEC 60320 versions C13 and C14 prove less than ideal. Thevoltage drops across the complete interconnect path including the inputAC line cord and power inlet connector from the line source to theneutral return can approach 1 volt at 11.5 amps. This results in a powerloss of approximately 11.5 watts which is roughly equivalent to a 0.7%penalty in the overall efficiency ratings of a 1200 watt, 87% efficientPSU. Such losses largely originate from two sources: 1.) The voltagedrops in the IEC320 power cord are a result of the use of cable withinsufficient diameter (the AWG rating and resistance is too high); 2.)The voltage drops in the IEC320 inlet originate from high contactresistance between the inlet and the mating end of the power cord.

Further, current PSUs use an array of modular cables for direct current(DC) output from the PSU. Such modular cables incorporate sub-optimalconnectors having too high contact resistance and wire of too highseries resistance and are not optimal for supplying sufficient currentwhile minimizing power losses to key chips on motherboards, daughtercards such as video controller cards, and peripheral devices associatedwith the computer, for example.

A further problem is the way in which such sub-optimal connectors arewired to the DC output electronics of the PSU. Presently, bundles ofwires are used to connect the PSU circuit board containing the DC outputregulators to another circuit board containing an array of connectorsrequired when implementing modular cables.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a high-level schematic that illustrates the use of IEC 60309as an AC interconnect for a PSU, according to certain embodiments.

FIG. 2 illustrates some international plug types, according to certainembodiments.

FIG. 3A and FIG. 3B illustrate the use of a terminal block in an ACinterconnect scheme for use with a PSU that is compatible with PCs andworkstations, according to certain embodiments.

FIG. 4 illustrates the use of a circular connector in an AC interconnectscheme for use with a PSU that is compatible with PCs and workstations,according to certain embodiments.

FIG. 5 illustrates the use of a rectangular connector in an ACinterconnect scheme for use with a PSU that is compatible with PCs andworkstations, according to certain embodiments.

FIG. 6 illustrates the use of a direct connection in an AC interconnectscheme for use with a PSU that is compatible with PCs and workstations,according to certain embodiments.

FIG. 7 illustrates the use of a direct connection in an AC interconnectscheme in conjunction with a connector to join a portion of the AC cablethat includes the AC plug to the rest of the AC cable connected to theprinted circuit board for use with a PSU that is compatible with PCs andworkstations, according to certain embodiments.

FIGS. 8A-C illustrate the use of multiple connectors associated with ACpower cables on a PSU, according to certain embodiments.

FIG. 9 illustrates the use of a terminal block in a DC modular cableinterconnect scheme for use with a PSU that is compatible with PCs andworkstations, according to certain embodiments.

FIG. 10 illustrates the use of a circular connector in a DC modularcable interconnect scheme for use with a PSU that is compatible with PCsand workstations, according to certain embodiments.

FIG. 11 illustrates the use of a rectangular connector in a DC modularcable interconnect scheme for use with a PSU that is compatible with PCsand workstations, according to certain embodiments.

FIG. 12 illustrates the use of wave crimp connectors in a DC modularcable interconnect scheme for use with a PSU that is compatible with PCsand workstations, according to certain embodiments.

FIG. 13 illustrates the use of bus bars and clamps in a DC modular cableinterconnect scheme for use with a PSU that is compatible with PCs andworkstations, according to certain embodiments.

FIG. 14 illustrates the use of an extended horizontal printed circuitboard (PCB) in a DC modular cable interconnect scheme for use with a PSUthat is compatible with PCs and workstations, according to certainembodiments.

FIG. 15 illustrates the use of an extended horizontal printed circuitboard (PCB) in a DC modular cable interconnect scheme for use with a PSUthat is compatible with PCs and workstations, according to certainembodiments.

FIG. 16 illustrates the use of a pin interface between the horizontalPCB and the vertical connector PCB to replace the wire bundle that wouldhave been used to hard wire the horizontal PCB to the vertical connectorPCB in a PSU, according to certain embodiments.

FIG. 17 illustrates the use of an array of high current connectors tointerface between the horizontal PCB and the vertical connector PCB toreplace the wire bundle that would have been used to hard wire thehorizontal PCB to the vertical connector PCB in a PSU, according tocertain embodiments.

FIG. 18 illustrates the use of multiple arrays of connector fingers andmultiple high pin count connectors as an interface between thehorizontal PCB and the vertical connector PCB to replace the wire bundlethat would have been used to hard wire the horizontal PCB to thevertical connector PCB in a PSU, according to certain embodiments.

FIG. 19 illustrates the use of multiple wide fingers and correspondingmilled slits as an interface between the horizontal PCB and the verticalconnector PCB to replace the wire bundle that would have been used tohard wire the horizontal PCB to the vertical connector PCB in a PSU,according to certain embodiments.

FIG. 20 illustrates the use of an array of right angle metal brackets tointerface between the horizontal PCB and the vertical connector PCB toreplace the wire bundle that would have been used to hard wire thehorizontal PCB to the vertical connector PCB in a PSU, according tocertain embodiments.

FIG. 21 illustrates the use of an array of straight metal brackets andcorresponding milled slits to interface between the horizontal PCB andthe vertical connector PCB to replace the wire bundle that would havebeen used to hard wire the horizontal PCB to the vertical connector PCBin a PSU, according to certain embodiments.

FIG. 22 illustrates the use of braided flat cables and correspondingmilled slits interface between the horizontal PCB and the verticalconnector PCB to replace the wire bundle that would have been used tohard wire the horizontal PCB to the vertical connector PCB in a PSU,according to certain embodiments.

FIG. 23 illustrates the use of a plurality of connector arrays mounteddirectly on a horizontal PCB, the plurality of connector arrays for useas DC modular cable outlets, according to certain embodiments.

DETAILED DESCRIPTION

According to certain embodiments, the PSUs as described herein complywith the standards specified in the Advanced Technology Extended (ATX)specification.

The standard specification for the contact resistance for a mated pairof IEC 320 contacts is about 10 milliohms. By reducing both the cableresistance and the contact resistance, the power loss created by anexisting AC interconnect scheme can be reduced, according to certainembodiments. This would reduce the power wasted in the cable/inletcombination, thereby increasing the overall efficiency of the system.Further, the temperature of the power cable would be reduced.

According to certain embodiments, a variety of AC interconnect schemescan replace an IEC 60320 C13 power cord inserted in an IEC 60320 C14inlet for AC interconnect for use with high current power supply unitsthat are compatible with computers such as personal computers andworkstations. Features of suitable replacement AC interconnect schemesinclude the ability to support comparatively low gauge wire that offerslow series resistance coupled with connectors that offer low contactresistance at connector mating interfaces, according to certainembodiments. Further, such replacement interconnect schemes permit theuse of a variety of AC plugs depending on the country (and itselectrical codes) in which the PSU is used so that power can be sourcedin any country in the world. According to some embodiments, the varietyof AC interconnect schemes do not replace an IEC 60320 C13 power cordinserted in an IEC 60320 C14 inlet but rather are added to the powersupply units for purposes of achieving backwards compatibility with theexisting industry standard. A non-limiting example of a suitable ACinterconnect is the IEC 60309. The IEC 60309 has higher AC currentcapabilities than the IEC 60320. FIG. 1 is a high-level schematic thatillustrates the use of IEC 60309 as an AC interconnect for a PSU,according to certain embodiments.

According to certain embodiments, FIG. 1 shows a PSU chassis 102, an ACinterconnect 100 that includes a power cable 106, AC plug 110, an IEC60309 plug 108 that plugs into IEC 60309 receptacle 104. IEC 60309receptacle 104 is on PSU chassis 102. Voltage drops at high currentsacross a single IEC 60320 C13 AC cable are reduced. Less heat isdissipated than in the standardized single IEC 60320 C14 chassis pluginlet. Overall efficiencies are thus increased. The AC plug 110 shown inFIG. 1 is a standard AC plug that is compatible with US electricalstandards. However, the AC plug can be any international plug typedepending on the country in which the PSU is used. Some non-limitingexamples of AC plug types are shown in FIG. 2.

FIG. 2 illustrates international plug types 202, 204, 206, 208 and 210,according to certain embodiments. The embodiments are not limited to theinternational plug types shown in FIG. 2.

As previously mentioned, the embodiments are not limited to the IEC60309 as a suitable AC interconnect. Various AC interconnect schemes canbe used in the embodiments. FIGS. 3-6 show a variety of AC interconnectschemes that can replace the IEC 60320 C13 power cord inserted into asingle IEC 60320 C14 inlet, according to certain embodiments.

According to certain embodiments, FIG. 3A illustrates the use of aterminal block in an AC interconnect scheme for use with a PSU that iscompatible with PCs and workstations. FIG. 3A shows a PSU chassis 302,an AC interconnect 300 that includes an AC power cable 312, AC plug 314,a terminal cover 308 and spade or lug terminals 310 that are screwedonto a terminal block 304 mounted on a printed circuit board 306 (PCB)inside PSU chassis 302. For example, the stripped ends of each wirecomprising AC power cable 312 may be crimped or soldered to theappropriate end of each spade or lug terminal 310. Terminal block 304replaces the standard IEC 60320 inlet. Terminal cover 308 may be aremovable cover that meets international electrical safety standards.The AC power cable 312 has conductors with a wire gauge suitable for lowvoltage drops at high currents (e.g., less than AWG 16 gauge). In suchan AC interconnect scheme, the voltage drops at high currents across theAC cable are reduced. Less heat is dissipated in terminal block 304 thanin the standardized single IEC 60320 C14 chassis plug inlet. Overallefficiencies are thus increased. The AC plug 314 shown in FIG. 3A is astandard AC plug that is compatible with US electrical standards.However, the AC plug can be any international plug type depending on thecountry in which the PSU is used. As previously mentioned, non-limitingexamples of AC plug types are shown in FIG. 2. According to certainother embodiments, spade terminals 310 can be bolted directly to theprinted circuit board 306 (PCB) inside PSU chassis 302. In such anembodiment, terminal block 304 is not used. According to yet otherembodiments, no spade or lug terminals are used for connecting to sometypes of terminal blocks. For example, FIG. 3B shows a terminal block316. Terminal block 316 includes wire receptacles 318 that can receivestripped ends of each wire comprising a power cable (not shown in FIG.3B). Such stripped ends can be tinned with solder, for example, and aresecured to terminal block 316 by tightening set screws 320 to clamp downon the stripped ends. Terminal block 316 can be secured to the printedcircuit board (PCB) inside PSU chassis by solder pins 322.

According to certain embodiments, FIG. 4 illustrates the use of acircular connector in an AC interconnect scheme for use with a PSU thatis compatible with PCs and workstations. FIG. 4 shows a PSU chassis 402,an AC interconnect 400 that includes an AC power cable 408, AC plug 410and a circular free hanging connector 406 that mates with circular panelmount connector 404 mounted on a PSU chassis 402. For example, thestripped ends of each wire comprising AC power cable 408 can be solderedor crimped to the pins (not shown) that can be inserted into circularfree hanging connector 406. Circular free hanging connector 406 andcircular panel mount connector 404 may have threaded housings so thatcircular free hanging connector 406 can be screwed onto the circularpanel mount connector 404, for example. As another example, circularfree hanging connector 406 and the circular panel mount connector 404have bayonet type housings to allow the circular free hanging connector406 to be mated to the circular panel mount connector 404. Circularpanel mount connector 404 replaces the standard IEC 60320 inlet. The ACpower cable 408 has conductors with a wire gauge suitable for lowvoltage drops at high currents (e.g., less than AWG 16 gauge). In suchan AC interconnect scheme, the voltage drops at high currents across theAC cable are reduced. Less heat is dissipated in circular panel mountconnector 404 than in the standardized single IEC 60320 C14 chassis pluginlet. Overall efficiencies are thus increased. The AC plug 410 shown inFIG. 4 is a standard AC plug that is compatible with US electricalstandards. However, the AC plug can be any international plug typedepending on the country in which the PSU is used. As previouslymentioned, non-limiting examples of AC plug types are shown in FIG. 2.

According to certain embodiments, FIG. 5 illustrates the use of arectangular connector in an AC interconnect scheme for use with a PSUthat is compatible with PCs and workstations. FIG. 5 shows a PSU chassis502, an AC interconnect 500 that includes an AC power cable 508, AC plug510 and a rectangular free hanging connector 506 that mates withrectangular panel mount connector 504 mounted on a PSU chassis 502. Forexample, the stripped ends of each wire comprising AC power cable 508can be soldered or crimped to the pins (not shown) that can be insertedinto rectangular free hanging connector 506. Rectangular free hangingconnector 506 can be inserted into the complementary rectangular panelmount connector 504 (pins not shown). Rectangular free hanging connector506 and complementary rectangular panel mount connector 504 can havehousings that employ mechanical latching mechanism, or flexible plasticlatches or threaded fasteners, for example. Rectangular panel mountconnector 504 replaces the standard IEC 60320 inlet. The AC power cable508 has conductors with a wire gauge suitable for low voltage drops athigh currents (e.g., less than AWG 16 gauge). In such an AC interconnectscheme, the voltage drops at high currents across the AC cable arereduced. Less heat is dissipated in rectangular panel mount connector504 than in the standardized single IEC 60320 C14 chassis plug inlet.Overall efficiencies are thus increased. The AC plug 510 shown in FIG. 5is a standard AC plug that is compatible with US electrical standards.However, the AC plug can be any international plug type depending on thecountry in which the PSU is used. As previously mentioned, non-limitingexamples of AC plug types are shown in FIG. 2.

According to certain embodiments, FIG. 6 illustrates the use of a directconnection in an AC interconnect scheme for use with a PSU that iscompatible with PCs and workstations. FIG. 6 shows a PSU chassis 602,chassis rear shown removed 604, an AC interconnect 600 that includes anAC power cable 608, AC plug 610 and the stripped ends 606 of AC cablesoldered or bolted to the printed circuit board in the PSU chassis 602.The stripped ends 606 that are soldered or bolted to the printed circuitboard replace the standard IEC 60320 inlet. The AC power cable 608 hasconductors with a wire gauge suitable for low voltage drops at highcurrents (e.g., less than AWG 16 gauge). In such an AC interconnectscheme, the voltage drops at high currents across the AC cable arereduced. Less heat is dissipated in the stripped ends 606 that aresoldered or bolted to the printed circuit board than in the standardizedsingle IEC 60320 C14 chassis plug inlet. Overall efficiencies are thusincreased. The AC plug 610 shown in FIG. 6 is a standard AC plug that iscompatible with US electrical standards. However, the AC plug can be anyinternational plug type depending on the country in which the PSU isused. As previously mentioned, non-limiting examples of AC plug typesare shown in FIG. 2.

According to certain embodiments, FIG. 7 illustrates the use of a directconnection in an AC interconnect scheme in conjunction with a connectorto join a portion of the AC cable that includes the AC plug to the restof the AC cable connected to the printed circuit board for use with aPSU that is compatible with PCs and workstations. FIG. 7 shows a PSUchassis 702, chassis rear shown removed 704, an AC interconnect 700 thatincludes an AC power cable 708, AC plug 710, mated pair of connectors712, and the stripped ends 706 of AC cable soldered or bolted to theprinted circuit board in the PSU chassis 702. The stripped ends 706 thatare soldered or bolted to the printed circuit board replace the standardIEC 60320 inlet. The mated pair of connectors 712 connect the portion ofthe AC cable 708 that includes the AC plug to the rest of the AC cableconnected to the printed circuit board. The AC power cable 708 hasconductors with a wire gauge suitable for low voltage drops at highcurrents (e.g., less than AWG 16 gauge). In such an AC interconnectscheme, the voltage drops at high currents across the AC cable arereduced. Less heat is dissipated in the combination of the connectorjoined to complementary mating connector 712 and AC cable solderedinternally 706 than in the standardized single IEC 60320 C14 chassisplug inlet. Overall efficiencies are thus increased. The AC plug 710shown in FIG. 7 is a standard AC plug that is compatible with USelectrical standards. However, the AC plug can be any international plugtype depending on the country in which the PSU is used. As previouslymentioned, non-limiting examples of AC plug types are shown in FIG. 2.

According to certain embodiments, FIGS. 8A-C illustrate the use ofmultiple connectors associated with AC power cables on a PSU. Theimplementation illustrated in FIGS. 8A-C present an implementation thatis backward compatible with the existing IEC320 systems and also allowan option for installing a high efficiency AC power cable, thus limitingthe voltage drop and thereby reducing the power wasted in theinterconnect, according to certain embodiments. FIG. 8A shows twodissimilar inlets 804 and 806 mounted adjacent to one another on a PSUchassis 802. As a non-limiting example, inlet 806 may the standard IEC60320 C14 and inlet 804 is an inlet with a higher current carryingcapacity (e.g., IEC 60309 C14 inlet, terminal block, circular panelmount connector, or rectangular panel mount connector). Such aconfiguration allows a user to select between the standard IEC 60320 C14inlet 806 and the more robust inlet 804 that has a higher currentcarrying capacity.

According to certain embodiments, FIGS. 8B and 80 show a sliding door808. Sliding door 808 is configured such that either inlet 804 or inlet806 can be exposed for use. Sliding door 808 is a safety feature andcovers the inlet that is not in use.

According to certain embodiments, modular cables for direct current (DC)output from the PSU are designed with DC modular cable interconnectschemes. Each PSU may have multiple modular cables for use with variousperipherals of the computer. According to certain embodiments,connectors with lower contact resistance coupled with wire of higherdiameter are used to lower voltage drops and thus lower power losses.According to certain embodiments, a given DC modular cable has aconnector that has a large contact area at the end portion of the DCmodular cable that connects to the PSU. The other end of the DC modularcable that does not connect to the PSU ends in a connector that iscompatible with existing peripheral implementations. Further, each DCmodular cable has wiring of less than AWG 16 gauge. Such DC modularcable interconnect schemes reduce series resistance, increasereliability and reduce cost. Various DC modular cable interconnectschemes can be used in the embodiments. FIGS. 9-15 show a variety of DCcable interconnect schemes. For ease of explanation, each of FIGS. 9-15show only one connector on the PSU chassis. However, the embodiments arenot limited to only one modular cable. According to some embodiments,the PSU can include an array of connectors of various types or the sametype for use with a corresponding set of DC modular cables. Further, theinterconnect schemes as shown in FIGS. 9-15 include at least twoconductors, one for power and one for ground, according to certainembodiments. For example, the interconnect uses even multiples of twoconductors (multiple power-ground pairs). However, there may be specificcircumstances in which an odd number of conductors would be employed.FIGS. 12 -15 show two conductors for each interconnect.

According to certain embodiments, FIG. 9 illustrates the use of aterminal block in a DC modular cable interconnect scheme for use with aPSU that is compatible with PCs and workstations. FIG. 9 shows a PSUchassis 902, a DC modular cable interconnect 900 that includes a powercable 912, a connector 914 (not shown) for connecting to a computerperipheral and spade lugs 910 that are screwed onto a terminal block 904mounted on a printed circuit board (PCB) inside PSU chassis 902.Stripped ends of each wire comprising one end of power cable 912 can becrimped or soldered onto spade lugs 910, for example. Power cable 912has conductors with a wire suitable for low voltage drops at highcurrents (e.g., less than AWG 16 gauge). According to certainembodiments, no spade or lug terminals are used for connecting to sometypes of terminal blocks. For example, FIG. 3B shows a terminal block316. Terminal block 316 includes wire receptacles 318 that can receivestripped ends of each wire comprising a power cable (not shown in FIG.3B). Such stripped ends can be tinned with solder, for example, and aresecured to terminal block 316 by tightening set screws 320 to clamp onthe stripped ends. Terminal block 316 can be secured to the printedcircuit board (PCB) inside PSU chassis by solder pins 322.

According to certain embodiments, FIG. 10 illustrates the use of acircular connector in a DC modular cable interconnect scheme for usewith a PSU that is compatible with PCs and workstations. FIG. 10 shows aPSU chassis 1002, a DC modular cable interconnect 1000 that includes apower cable 1008, a connector 1010 (not shown) for connecting to acomputer peripheral and a circular free hanging connector 1006 thatmates with circular panel mount connector 1004 mounted on a PSU chassis1002. Stripped ends of each wire comprising power cable 1008 can besoldered or crimped to the pins (not shown) that can be inserted intocircular free hanging connector 1006, for example. Circular free hangingconnector 1006 and circular panel mount connector 1004 may have threadedhousings so that circular free hanging connector 1006 can be screwedonto the circular panel mount connector 1004, for example. As anotherexample, circular free hanging connector 1006 and the circular panelmount connector 1004 have bayonet type housings to allow the circularfree hanging connector 1006 to be mated to the circular panel mountconnector 1004. The power cable 1008 has conductors with a wire gaugesuitable for low voltage drops at high currents (e.g., less than AWG 16gauge).

According to certain embodiments, FIG. 11 illustrates the use of arectangular connector in a DC modular cable interconnect scheme for usewith a PSU that is compatible with PCs and workstations. FIG. 11 shows aPSU chassis 1102, a DC modular cable interconnect 1100 that includes apower cable 1108, connectors 1110 (not shown) for connecting to acomputer peripheral and a rectangular free hanging connector 1106 thatmates with rectangular panel mount connector 1104 mounted on a PSUchassis 1102. For example, the stripped ends of each wire comprising oneend of power cable 1108 can be soldered or crimped to the pins (notshown) that can be inserted into rectangular free hanging connector1106. Rectangular free hanging connector 1106 can be inserted into thecomplementary rectangular panel mount connector 1104 (pins not shown).Rectangular free hanging connector 1106 and complementary rectangularpanel mount connector 1104 can have housings that employ mechanicallatching mechanism, or flexible plastic latches or threaded fasteners,for example. The power cable 1108 has conductors with a wire gaugesuitable for low voltage drops at high currents (e.g., less than AWG 16gauge).

According to certain embodiments, FIG. 12 illustrates the use of a wavecrimp connector in a DC modular cable interconnect scheme for use with aPSU that is compatible with PCs and workstations. FIG. 12 shows a PSUchassis 1202, a DC modular cable interconnect 1200 that includes twopower cables 1208 (one for DC voltage and the other for ground return),a connector 1210 (not shown) for connecting to a computer peripheral anda wave crimp connector 1206 that mates with wave crimp chassis mountconnector 1204 mounted on a PSU chassis 1202. Wave crimp connector 1206can be inserted into the complementary wave crimp mount connector 1204.Each power cable 1208 has a single flat cable conductor with a wiregauge suitable for low voltage drops at high currents (e.g., less thanAWG 16 gauge).

According to certain embodiments, FIG. 13 illustrates the use of a busbar and clamp in a DC modular cable interconnect scheme for use with aPSU that is compatible with PCs and workstations. FIG. 13 shows a PSUchassis 1302, a DC modular cable interconnect 1300 that includes twoflat braided power cables 1308 (one for DC voltage and the other forground return), connectors 1310 (not shown) for connecting to a computerperipheral and clamp connectors 1306 that can be clamped tocorresponding bus bars connector 1304 mounted inside a PSU chassis 1302.According to certain embodiments, the metal bus bars are such that wiresof the DC modular cable can be secured to the bus bars by screwing,clamping, welding or soldering. The flat braided power cables 1308 aresuch that they are suitable for low voltage drops at high currents.According to certain embodiments, Litz wire can be used. According tocertain embodiments, the aluminum bus bars can be nickel plated first,and then optionally plated with gold to achieve lower contactresistance.

According to certain embodiments, FIG. 14 illustrates the use of anextended horizontal printed circuit board (PCB) in a DC modular cableinterconnect scheme for use with a PSU that is compatible with PCs andworkstations. FIG. 14 shows a PSU chassis 1402, a DC modular cableinterconnect 1400 that includes two flat power cables 1410 (one for DCvoltage and the other for ground return), connectors 1412 (not shown)for connecting to a computer peripheral, and an extended horizontal PCB1404 with PC fingers 1406. The flat power cables 1410 are clamped ontoPCB fingers 1406 using cable clamps 1408. According to certainembodiments, the flat cables 1410 can be secured to the PCB fingers 1406by screwing, clamping, welding or soldering. The flat power cables 1410are such that they are suitable for low voltage drops at high currents.According to certain embodiments, Litz wire can be used.

According to certain embodiments, FIG. 15 illustrates the use of anextended horizontal printed circuit board (PCB) in a DC modular cableinterconnect scheme for use with a PSU that is compatible with PCs andworkstations. FIG. 15 shows a PSU chassis 1502, a DC modular cableinterconnect 1500 that includes two power cables 1510 (one for DCvoltage and the other for ground return), connectors 1512 (not shown)for connecting to a computer peripheral, and an extended horizontal PCB1504 with PC fingers 1506. The power cables 1510 have lugs 1508 that areclamped onto PCB fingers 1506. According to certain embodiments, thecables 1510 can be secured to the PCB fingers 1506 by screwing,clamping, welding or soldering. The power cables 1510 are such that theyare suitable for low voltage drops at high currents.

According to certain embodiments, with respect to DC modular cables usedwith PSUs, instead of using a bundle of wires to hard wire the DC outputelectronics from a horizontally oriented PSU main PCB (horizontal PCB)containing the PSU's output electronics to a vertically oriented PCB(vertical connector PCB) where the modular cable connector outlets aremounted, various PCB interconnect schemes can be used as illustrated inFIGS. 16-23 to increase reliability and efficiency of the PSU. Accordingto some embodiments, such PCB interconnect schemes are low resistanceinterconnect schemes. For purposes of explanation, the embodiments aredescribed using a vertically oriented connector PCB and a horizontallyoriented PSU main PCB. However, the embodiments are not limited to suchan orientation.

According to certain embodiments, FIG. 16 illustrates the use of a pininterface between the horizontal PCB and the vertical connector PCB toreplace the wire bundle that would have been used to hard wire thehorizontal PCB to the vertical connector PCB in a PSU. FIG. 16 shows twovertical connector PCBs 1602 that are connected to horizontal PCB 1606through a respective array of pins 1604. Each vertical connector PCB isinstalled with one or more DC connector outlets 1603 to which DC modularcables can be connected. The embodiments are not limited to two verticalconnector PCBs. According to certain embodiments, the respective arrayof pins 1604, each of which is capable of carrying relatively highcurrents (on the order of a few amps), is soldered to its respectivevertical connector PCB. Each vertical connector PCB is soldered to thehorizontal PCB in the PSU which allows high currents to be transferredbetween vertical connector PCBs and the horizontal PCB with low voltagedrops. According to certain embodiments, there are N+1 vertical boards,where N is equal to or greater than 1. The Nth vertical board is closerto the opening of the power supply chassis than the N+1th verticalboard. The N+1th vertical board has a greater height that the Nthvertical board to allow DC connector outlets to be installed on each ofthe N vertical boards.

According to certain embodiments, FIG. 17 illustrates the use of a highcurrent connector array interface between the horizontal PCB and thevertical connector PCB to replace the wire bundle that would have beenused to hard wire the horizontal PCB to the vertical connector PCB in aPSU. FIG. 17 shows two vertical connector PCBs 1702 each verticalconnector PCB is installed with one or more DC connector outlets 1703 towhich DC modular cables can be connected. The embodiments are notlimited to two vertical connector PCBs. Soldered to each verticalconnector PCB 1702 is a respective high current connector array 1704.Each high current connector in the array 1704 comprises a large array ofpins, each of which is capable of carrying relatively high currents (onthe order of a few amps). Complementary mating connector arrays 1706 aresoldered to the horizontal PCB 1708 in the PSU. Each vertical connectorPCB 1702 can be connected to the horizontal PCB 1708 in the PSU bymating each high current connector array 1704 with its counterpartcomplementary mating connector array 1706, which allows high currents tobe transferred between vertical connector PCBs and the horizontal PCBwith low voltage drops. According to certain embodiments, there are N+1vertical boards, where N is equal to or greater than 1.The Nth verticalboard is closer to the opening of the power supply chassis than theN+1th vertical board. The N+1th vertical board has a greater height thatthe Nth vertical board to allow DC connector outlets to be installed oneach of the N vertical boards.

According to certain embodiments, FIG. 18 illustrates the use ofconnector fingers array and high pin count connector array interfacebetween the horizontal PCB and the vertical connector PCB to replace thewire bundle that would have been used to hard wire the horizontal PCB tothe vertical connector PCB in a PSU. FIG. 18 shows two verticalconnector PCBs 1802. each vertical connector PCB is installed with oneor more DC connector outlets 1803 to which DC modular cables can beconnected. The embodiments are not limited to two vertical connectorPCBs. Each vertical connector PCB 1802 is etched with a respective arrayof connector fingers 1804. Respective complementary high pin countconnector arrays 1806 are soldered to the horizontal PCB 1808 in thePSU. Each vertical connector PCB can be connected to the horizontal PCBin the PSU by mating each array connector fingers 1804 with itscounterpart complementary high pin count connector arrays 1806, whichallows high currents to be transferred between vertical connector PCBsand the horizontal PCB with low voltage drops. According to certainembodiments, there are N+1 vertical boards, where N is equal to orgreater than 1. The Nth vertical board is closer to the opening of thepower supply chassis than the N+1th vertical board. The N+1th verticalboard has a greater height that the Nth vertical board to allow DCconnector outlets to be installed on each of the N vertical boards.

According to certain embodiments, FIG. 19 illustrates the use of widefingers connector array and corresponding milled slits interface betweenthe horizontal PCB and the vertical connector PCB to replace the wirebundle that would have been used to hard wire the horizontal PCB to thevertical connector PCB in a PSU. FIG. 19 shows two vertical connectorPCBs 1902, each vertical connector PCB is installed with one or more DCconnector outlets 1903 to which DC modular cables can be connected. Theembodiments are not limited to two vertical connector PCBs. Eachvertical connector PCB 1902 is etched or routed with a plurality of widefingers 1904 separated by routed gaps, for example. Respectivecomplementary slits 1906 are milled into the horizontal PCB 1908 in thePSU. Each vertical connector PCB can be connected to the horizontal PCBin the PSU by mating each of wide fingers 1904 with its counterpartcomplementary slit 1906 on the horizontal PCB 1908 and soldering themated pair. The large trace areas on the wide fingers 1904 allow highcurrents to be transferred between vertical connector PCBs and thehorizontal PCB with low voltage drops. According to certain embodiments,the wide fingers 1904 and milled slits 1906 can be nickel plated first,and then optionally plated with gold to achieve lower contactresistance. According to certain embodiments, there are N+1 verticalboards, where N is equal to or greater than 1. The Nth vertical board iscloser to the opening of the power supply chassis than the N+1thvertical board. The N+1th vertical board has a greater height that theNth vertical board to allow DC connector outlets to be installed on eachof the N vertical boards.

According to certain embodiments, FIG. 20 illustrates the use of rightangle metal bracket interface between the horizontal PCB and thevertical connector PCB to replace the wire bundle that would have beenused to hard wire the horizontal PCB to the vertical connector PCB in aPSU. FIG. 20 shows two vertical connector PCBs 2002, each verticalconnector PCB is installed with one or more DC connector outlets 2003 towhich DC modular cables can be connected. The embodiments are notlimited to two vertical connector PCBs. FIG. 20 also shows a horizontalPCB 2008. Each vertical connector PCB 2002 and the horizontal PCB 2008includes respective plated areas 2006 to which are attachedcorresponding right angle metal brackets 2004. Each plated area 2006 hasat least one hole. For example, one edge of each right angle metalbracket 2004 makes contact with a corresponding copper area etched intoeach vertical PCB. On each right angle metal bracket 2004 may beinstalled two or more captive nuts. Screws may be inserted through theholes in the copper plated areas 2006 of each vertical PCB andhorizontal PCB and tightened into each right angle metal bracket 2004 atthe location of the corresponding captive nuts. Thus, each verticalconnector PCB 2002 is connected to the horizontal PCB 2008 in the PSUand allows high currents to be transferred between vertical connectorPCBs and the horizontal PCB with low voltage drops. According to certainembodiments, the right angle metal brackets 2004 and plated areas 2006can be nickel plated first, and then optionally plated with gold toachieve lower contact resistance. According to certain embodiments,there are N+1 vertical boards, where N is equal to or greater than 1.The Nth vertical board is closer to the opening of the power supplychassis than the N+1th vertical board. The N+1th vertical board has agreater height that the Nth vertical board to allow DC connector outletsto be installed on each of the N vertical boards.

According to certain embodiments, FIG. 21 illustrates the use ofstraight metal brackets and corresponding milled slits interface betweenthe horizontal PCB and the vertical connector PCB to replace the wirebundle that would have been used to hard wire the horizontal PCB to thevertical connector PCB in a PSU. FIG. 21 shows two vertical connectorPCBs 2102, each vertical connector PCB is installed with one or more DCconnector outlets 2103 to which DC modular cables can be connected. Theembodiments are not limited to two vertical connector PCBs. Eachvertical connector PCB 2102 includes copper plated areas 2104 to whichare attached corresponding straight metal brackets 2106. Each platedarea 2104 has at least one hole. For example, one edge of each straightmetal bracket 2106 makes contact with a corresponding area etched intoeach vertical PCB. On each straight metal bracket 2106 may be installedone or more captive nuts at locations where the vertical PCB is to besecured to the straight metal brackets 2106. Screws may be insertedthrough the holes in the copper plated areas 2104 of each vertical PCBand tightened into each metal bracket 2106 at the location of thecorresponding captive nut. Respective complementary slits 2108 aremilled into the horizontal PCB 2110 in the PSU. Each vertical connectorPCB 2102 can be connected to the horizontal PCB 2110 in the PSU bymating each of the metal brackets 2106 into its counterpartcomplementary slit 2108 on the horizontal PCB 2110 and soldering themated pair. According to certain embodiments, the metal brackets 2106are plated with an alloy that allows them to be soldered into slits2108. According to certain embodiments straight metal brackets can benickel plated first, and then optionally plated with gold to achievelower contact resistance. Thus, each vertical connector PCB 2102 isconnected to the horizontal PCB 2108 in the PSU and allows high currentsto be transferred between vertical connector PCBs and the horizontal PCBwith low voltage drops. According to certain embodiments, there are N+1vertical boards, where N is equal to or greater than 1. The Nth verticalboard is closer to the opening of the power supply chassis than theN+1th vertical board. The N+1th vertical board has a greater height thatthe Nth vertical board to allow DC connector outlets to be installed oneach of the N vertical boards.

According to certain embodiments, FIG. 22 illustrates the use of braidedflat cable and corresponding milled slits interface between thehorizontal PCB and the vertical connector PCB to replace the wire bundlethat would have been used to hard wire the horizontal PCB to thevertical connector PCB in a PSU. FIG. 22 shows two vertical connectorPCBs 2202, each vertical connector PCB is installed with one or more DCconnector outlets 2203 to which DC modular cables can be connected. Theembodiments are not limited to two vertical connector PCBs. Eachvertical connector PCB 2202 includes copper plated areas 2204 to whichare attached corresponding flat braided cables 2206. Each plated area2204 has at least one hole. For example, one edge of each flat braidedcable 2206 makes contact with a corresponding area etched into eachvertical PCB. Behind each flat braided cable 2206 may be installed flatwashers and nuts (not shown) at locations where the vertical PCB is tobe secured to the flat braided cables 2206. Screws (not shown) may beinserted through the holes in the copper plated areas 2204 of eachvertical PCB through each flat braided cable 2206 and flat washer (notshown) and secured by the corresponding nut (not shown). Respectivecomplementary slits 2208 are milled into the horizontal PCB 2210 in thePSU. Each vertical connector PCB 2202 can be connected to the horizontalPCB 2210 in the PSU by mating each of the flat braided cables 2206 intoits counterpart complementary slit 2208 on the horizontal PCB 2210 andsoldering the mated pair. According to certain embodiments, the flatbraided cables 2206 are plated with an alloy that allows them to besoldered into slits 2208. According to certain embodiments metalbrackets can be nickel plated first, and then optionally plated withgold to achieve lower contact resistance. Thus, each vertical connectorPCB 2202 is connected to the horizontal PCB 2208 in the PSU and allowshigh currents to be transferred between vertical connector PCBs and thehorizontal PCB with low voltage drops. According to certain embodiments,there are N+1 vertical boards, where N is equal to or greater than 1.The Nth vertical board is closer to the opening of the power supplychassis than the N+1th vertical board. The N+1th vertical board has agreater height that the Nth vertical board to allow DC connector outletsto be installed on each of the N vertical boards.

According to certain embodiments, FIG. 23 illustrates the use of aplurality of connector arrays mounted directly on a horizontal PCB, theplurality of connector arrays for use as DC modular cable outlets. FIG.23 shows a PSU chassis 2302, a horizontal printed circuit board (PCB)2310 and a plurality of connector rows 2304 (only 2 rows are shown andwherein the plurality is two or more rows) mounted directly on ahorizontal PCB 2310. The plurality of connector rows 2304 is not limitedto 2 rows. According to certain embodiments, there may be more than 2rows. Each of the connectors in the connector rows 2304 serve as a DCmodular cable outlet. FIG. 23 shows one of the connector rows 2304oriented horizontally while the other connector row 2304 is orientedvertically. According to certain embodiments, the plurality of connectorrows 2304 may all be oriented vertically According to other embodiments,the first set of connector rows 2304 closest to the chassis wall(outermost row of connectors) is oriented horizontally while the rest ofthe plurality of connector rows 2304 are oriented vertically. Accordingto certain other embodiments, the plurality of connector rows 2304 maybe used in conjunction with N vertical boards as described herein withreference to FIGS. 16-22, where N is equal to or greater than 1. Theplurality of connector rows 2304 are closer to the opening of the powersupply chassis than the N vertical boards. The N−1th vertical board iscloser to the opening of the power supply chassis than the Nth verticalboard. The Nth vertical board has a greater height that the N−1thvertical board to allow DC connector outlets to be installed on each ofthe N vertical boards. According to certain embodiments, only oneconnector row 2304 is used in conjunction with N+1 vertical boards,where N is equal to or greater than 1. The single connector row 2304 iscloser to the opening of the power supply chassis than the N+1 verticalboards. The Nth vertical board is closer to the opening of the powersupply chassis than the N+1th vertical board. The N+1th vertical boardhas a greater height that the Nth vertical board to allow DC connectoroutlets to be installed on each of the N+1 vertical boards

In the foregoing specification, embodiments of the invention have beendescribed with reference to numerous specific details that may vary fromimplementation to implementation. Thus, the sole and exclusive indicatorof what the invention is and what is intended by the applicants to bethe invention, is the set of claims that issue from this application, inthe specific form in which such claims issue, including any subsequentcorrection. Any express definitions set forth herein for terms containedin such claims shall govern the meaning of such terms as used in theclaims. Hence, no limitation, element, property, feature, advantage orattribute that is not expressly recited in a claim should limit thescope of such claim in any way. The specification and drawings are,accordingly, to be regarded in an illustrative rather than a restrictivesense.

1. An ATX compatible power supply unit for use with a computer, the ATXcompatible power supply unit comprising: a chassis; at least one DCpower outlet mounted on the ATX compatible power supply unit, the atleast one DC power outlet comprising at least two contacts; and at leastone DC power cable comprising at least two individual conductors thatconnect to the at least one DC power outlet, wherein the at least one DCpower outlet is configured to support nominal contact resistances ofless than 2.5 milliohms per contact, or the at least one DC power cableis configured to support series resistances of less than 4 milliohms perlinear foot of individual conductor.
 2. The ATX compatible power supplyunit of claim 1, wherein the at least two individual conductors connectto the at least one DC power outlet through any one of connector pins,terminals and lugs.
 3. The ATX compatible power supply unit of claim 1,wherein the at least one DC power outlet supports contact resistances ofless than 2 milliohms per contact.
 4. The ATX compatible power supplyunit of claim 1, wherein the at least one DC power outlet supportscontact resistances of less than 1.5 milliohms per contact.
 5. The ATXcompatible power supply unit of claim 1, wherein the at least one DCpower outlet supports contact resistances of less than 1 milliohm percontact.
 6. The ATX compatible power supply unit of claim 1, wherein theat least one DC power outlet supports contact resistances of less than0.5 milliohms per contact.
 7. The ATX compatible power supply unit ofclaim 1, wherein the at least one DC power cable is configured tosupport series resistances of less than 3 milliohms per linear foot ofindividual conductor.
 8. The ATX compatible power supply unit of claim1, wherein the at least one DC power cable is configured to supportseries resistances of less than 2.5 milliohms per linear foot ofindividual conductor.
 9. The ATX compatible power supply unit of claim1, wherein the at least one DC power cable is configured to supportseries resistances of less than 1.5 milliohms per linear foot ofindividual conductor.
 10. The ATX compatible power supply unit of claim1, wherein the at least one DC power cable is configured to supportseries resistances of less than 1 milliohm per linear foot of individualconductor.
 11. The ATX compatible power supply unit of claim 1, whereinthe at least one DC power cable is configured to support seriesresistances of less than 0.6 milliohms per linear foot of individualconductor.
 12. The ATX compatible power supply unit of claim 1, whereinthe at least one DC power cable is configured to support seriesresistances of less than 0.4 milliohms per linear foot of individualconductor.
 13. The ATX compatible power supply unit of claim 1, whereinthe at least one DC power outlet and the at least one DC power cablesupport wave crimp connectors.
 14. The ATX compatible power supply unitof claim 1, wherein the at least one DC power outlet is a terminalblock.
 15. The ATX compatible power supply unit of claim 1, wherein theat least one DC power outlet and the at least one DC power cable supportcircular mating connectors.
 16. The ATX compatible power supply unit ofclaim 1, wherein the at least one DC power outlet and the at least oneDC power cable support rectangular mating connectors.
 17. The ATXcompatible power supply unit of claim 1, wherein the at least one DCpower outlet includes at least two metal bus bars to which each wire ofthe at least one DC power cable can be secured by any one of screwing,clamping, welding and soldering.
 18. The ATX compatible power supplyunit of claim 1, wherein the at least one DC power outlet and the atleast one DC power cable have housings that employ any one of mechanicallatching mechanisms, rotating latching mechanisms, flexible plasticlatches or threaded fasteners.
 19. The ATX compatible power supply unitof claim 1, further comprising a plurality of DC power outlets mountedon the ATX compatible power supply unit configured to mate withrespective DC power cables, wherein the plurality of DC power outletscan be any combination selected from terminal block, circular panelmount, and rectangular panel mount, metal bus bar.
 20. The ATXcompatible power supply unit of claim 1, wherein the at least one DCpower cable supports braided wire.
 21. The ATX compatible power supplyunit of claim 1, wherein the at least one DC power cable supports litzwire.
 22. The ATX compatible power supply unit of claim 19, wherein theplurality of DC power outlets and the respective DC power cables havehousings that employ any one of mechanical latching mechanisms, rotatinglatching mechanisms, flexible plastic latches or threaded fasteners. 23.The ATX compatible power supply unit of claim 1, further comprising amain printed circuit board that has an extended portion through a cutoutin the chassis, wherein the extended portion is routed into a pluralityof sub-portions, the sub-portions being plated with conductive material.24. The ATX compatible power supply unit of claim 23, wherein DC powercables with metal bracket terminations are connected to the platedsub-portions by any one of: soldering, clamps, or bolts
 25. The ATXcompatible power supply unit of claim 23, wherein DC power cables withlug terminations are connected to the plated sub-portions by bolts. 26.The ATX compatible power supply unit of claim 1, further comprising amain printed circuit board that has an extended portion through a cutoutin the chassis, wherein the extended portion includes two or more arraysof outlet connectors for use with corresponding DC power cables.
 27. TheATX compatible power supply unit of claim 26, wherein the two or morearrays of outlet connectors are oriented vertically.
 28. The ATXcompatible power supply unit of claim 26, wherein the outermost array ofoutlet connectors is oriented horizontally and the remainder of the twoor more arrays of outlet connectors are oriented vertically.